Stator structures

ABSTRACT

Stator structures are provided. A stator structure includes at least a magnetic conductive layer and at least an auxiliary magnetic polar layer. The magnetic conductive layer comprises a plurality of first poles. The auxiliary magnetic polar layer is disposed above the magnetic conductive layer, below the magnetic conductive layer, or between two magnetic conductive layers. The auxiliary magnetic polar layer comprises at least a second pole and a third pole. The total number of the second and the third poles is equal to that of the first poles. The second pole comprises permanent magnetic material.

BACKGROUND

The invention relates to stator structures.

FIG. 1 shows the structure of a conventional brushless direct current (DC) motor disclosed by U.S. Pat. No. 6,013,966. The brushless DC motor includes a stator structure. The stator structure includes an upper yoke 10 and an under yoke 20. A power coil is wound between the upper yoke 10 and the under yoke 20. The stator structure is an axial stator structure. A plurality of salient poles 1 conducts corresponding poles to drive a rotor 2 to rotate when the power coil is supplied with current.

The brushless DC motor further includes two permanent magnets 3 disposed outside the rotor 2 for fixing the rotor 2 at a start-up position, thus providing an appropriate start-up torque.

To generate a sufficient start-up torque, two permanent magnets 3 are located at two fixed positions. The included angle between the stator and each permanent magnet 3 is precisely θ. To fix the rotor 2 at a start-up position utilizing the two permanent magnets 3, the rotor 2 is covered with non-magnetic conductive material such as plastics. Thus the magnetic force between the stator and the rotor 2 is reduced, and a torque of the rotor 2 is influenced during rotation.

SUMMARY

Stator structures are provided. An exemplary embodiment of a stator structure comprises at least a magnetic conductive layer and at least an auxiliary magnetic polar layer. The magnetic conductive layer comprises a plurality of first poles. The auxiliary magnetic polar layer is disposed above the magnetic conductive layer, below the magnetic conductive layer, or between two magnetic conductive layers. The auxiliary magnetic polar layer comprises at least a second pole and a third pole, wherein the total number of the second and the third poles is equal to that of the first poles, and the second pole comprises permanent magnetic material.

Some embodiments of a stator structure comprise at least a magnetic conductive layer, at least a first auxiliary magnetic polar layer, and at least a second auxiliary magnetic polar layer. The magnetic conductive layer comprises a plurality of first poles. The first auxiliary magnetic polar layer is disposed above the magnetic conductive layer. The first auxiliary magnetic polar layer comprises at least a second pole and a third pole, wherein the total number of the second and the third poles is equal to that of the first poles, and the second pole comprises permanent magnetic material. The second auxiliary magnetic polar layer is disposed below the magnetic conductive layer or between two magnetic conductive layers. The second auxiliary magnetic polar layer comprises at least a fourth pole and a fifth pole, wherein the fourth and the fifth poles are disposed corresponding to positions of the second and the third poles respectively, and the fourth pole comprises permanent magnetic material.

Some embodiments of a stator structure comprise at least a magnetic conductive layer and at least a first auxiliary magnetic polar layer. The magnetic conductive layer comprises a plurality of first poles. The first auxiliary magnetic polar layer comprises at least a second pole, wherein the second pole comprises permanent magnetic material.

DESCRIPTION OF THE DRAWINGS

Stator structures can be more fully understood by reading the subsequent detailed description and examples with references made to the accompanying drawings, wherein:

FIG. 1 shows the structure of a conventional brushless direct current (DC) motor.

FIG. 2A shows the structure of an embodiment of a brushless direct current (DC) motor.

FIG. 2B shows the structure of an embodiment of a brushless direct current (DC) motor.

FIG. 3 shows the structure of an embodiment of a salient pole.

FIGS. 4A-4C show methods for disposing an auxiliary magnetic polar layer of an embodiment of a stator structure.

FIG. 5 shows the structure of an embodiment of a brushless direct current (DC) motor.

FIGS. 6A-6F show methods for disposing an auxiliary magnetic polar layer of an embodiment of a stator structure.

FIG. 7 shows a driving circuit of an embodiment of a brushless DC motor.

FIG. 8 is an output voltage to time graph when a brushless DC motor rotates.

DETAILED DESCRIPTION

Stator structures will be described in greater detail in the following.

In an exemplary embodiment of a stator structure, a permanent magnet is disposed on a stator and inside a rotor to drive the rotor to rotate, thus eliminating the need for a permanent magnet to be located at a precise position.

FIG. 2A shows the structure of an embodiment of a brushless direct current (DC) motor. The brushless DC motor comprises a stator 150 and a rotor 50. The rotor 50 is an annular magnet disposed around the stator 150 and coaxial with the stator 150. The stator 150 is an axial stator structure comprising an upper yoke 80 and an under yoke 90 disposed at an upper layer 60 and an under layer 70 thereof respectively. A permanent magnet 18 is symmetrically disposed between two salient poles 100 of the upper layer 60 of the stator 150. The outer layer, magnetically N-pole, of the permanent magnet 18 is an auxiliary magnetic polar layer for driving the rotor 50 to rotate.

FIG. 2B shows the structure of an embodiment of a brushless direct current (DC) motor. In this embodiment, an additional permanent magnet 19 is disposed between two salient poles 100 of the under layer 70 of the stator 150. The outer layer, magnetic S-pole, of the permanent magnet 18 is an auxiliary magnetic polar layer for driving the rotor 50 to rotate.

FIG. 3 shows the structure of an embodiment of a salient pole. Each salient pole, or magnetic pole, comprises a plurality of magnetic conductive layers 101. The permanent magnet 18 provides an auxiliary magnetic polar layer for the stator 150. Each permanent magnet 18 can be selectively disposed above the magnetic conductive layers 101, below the magnetic conductive layers 101, or between two magnetic conductive layers 101.

FIGS. 4A-4C show methods for disposing an auxiliary magnetic polar layer of an embodiment of a stator structure. In FIGS. 4A and 4B, the two permanent magnets 18 and 19 are parallel and corresponding, and disposed at the upper layer 60 and the under layer 70 respectively. The outer layers of the two permanent magnets 18 and 19 are magnetically identical. For example, in FIG. 4A, the permanent magnet 18 is disposed above the salient pole 100 of the upper layer 60, and the permanent magnet 19 is disposed between the two salient poles 100 of the under layer 70. The outer layers of the two permanent magnets 18 and 19 are magnetically identical, such as N-pole or S-pole. In FIG. 4C, the two permanent magnets 18 and 19 are interlaced and disposed at the upper layer 60 and the under layer 70 respectively. The outer layers of the two permanent magnets 18 and 19 are magnetically opposite. For example, in FIG. 4C, the permanent magnet 18 is disposed between the two salient poles 100 of the upper layer 60, and the permanent magnet 19 is disposed between the two salient poles 100 of the under layer 70. The outer layers of the two permanent magnets 18 and 19 are magnetically N-pole and S-pole respectively.

FIG. 5 shows the structure of an embodiment of a brushless direct current (DC) motor. The brushless DC motor comprises a stator comprising a yoke 180, a plurality of salient poles A, B, C, and D, and a plurality of permanent magnets 28. The stator is a radial stator structure. At least one of the permanent magnets 28 is disposed on at least one of the salient poles. For example, the permanent magnet 28 can be disposed on the salient poles C and D. The brushless DC motor further comprises a rotor 50. The rotor 50 is an annular magnet coaxially with and outside the stator, wherein poles Sa and Sb are magnetically S-pole, and poles Na and Nb are magnetically N-pole. When necessary, the rotor 50 can be disposed inside the stator.

FIGS. 6A-6F show methods for disposing an auxiliary magnetic polar layer of an embodiment of a stator structure. Outer layers of two permanent magnets on two opposite salient poles are magnetically identical, and outer layers of two permanent magnets on two adjacent salient poles are magnetically opposite. For example, in FIG. 6A, if the outer layer of the permanent magnet 28 on the salient pole A is magnetically N-pole, the outer layer of the permanent magnet 28 on the opposite salient pole B is magnetically N-pole, and the outer layers of the permanent magnet 29 on the adjacent salient poles C and D are both magnetically S-pole. In FIGS. 6A-6F, locations 27 corresponding to the permanent magnets 28 and 29 are provided with silicon steel, ferromagnetic material, permanent magnets, soft magnetic material, plastic magnets, rubber magnets, magnet-cored plastics, or non-magnetic conductive material such as plastics. If the material at location 27 is magnetic, the material and the corresponding permanent magnet 28 or 29 are magnetically opposite. Alternatively, the corresponding locations 27 can be holes.

For example, in FIG. 6A, the stator 51 comprises magnetic poles A, B, C, and D. Each magnetic pole comprises five magnetic sub-poles. The sub-pole having the permanent magnet 28 and the sub-pole at the corresponding location 27 constitute a first auxiliary magnetic polar layer. The sub-pole having the permanent magnet 29 and the sub-pole at the corresponding location 27 constitute a second auxiliary magnetic polar layer. The middle three sub-poles of magnetic poles A, B, C, and D constitute three magnetic conductive layers. Thus, the first auxiliary magnetic polar layer is above the three magnetic conductive layers, and the second auxiliary magnetic polar layer is below the three magnetic conductive layers. Each auxiliary magnetic polar layer contains a portion of magnetic poles A, B, C, and D. Each magnetic conductive layer contains a portion of magnetic poles A, B, C, and D. Thus, the number of magnetic poles relating to the magnetic conductive layer is equal to the number of magnetic poles relating to each magnetic conductive layer.

In FIGS. 6D-6F, the permanent magnet 28 or 29 is located at a middle sub-pole. Thus, the auxiliary magnetic polar layer is disposed between two magnetic conductive layers. The permanent magnet 28 or 29 comprises permanent magnetic material, such as a permanent magnet, a plastic magnet, a rubber magnet, or a magnet-cored plastic. The salient pole, or magnetic pole, comprises magnetic conductive material, such as ferromagnetic material or soft magnetic material.

FIG. 7 shows a driving circuit of an embodiment of a brushless DC motor. The driving circuit 700 comprises a power coil L1, a conduction coil L2, a start-up device 710, a control device 720, and a voltage detection device 730. The driving circuit 700 is described as below in reference to the brushless DC motor in FIG. 5. The power coil L1 in FIG. 5 and the power coil L1 in FIG. 7 are the same. The conduction coil L2 in FIG. 5 and the conduction coil L2 in FIG. 7 are the same. A diode D2 is added at a DC current input end (Vdc) to prevent reverse current. Resistors R, R1, R2, and R3 are added in the driving circuit 700 to prevent overflow current. A Zener diode ZD is added in the control device 720 to stabilize voltage.

If the DC current Vdc is 12V, the transistor Q1 is a PNP transistor, the transistor Q2 is a NPN transistor, and the permanent magnet 28 is magnetically N-pole. When the start-up device is coupled to the DC current Vdc, the transistor Q1 is turned on due to a reverse base-emitter voltage (12V) greater than a reverse junction voltage (0.7V). When the transistor Q1 is turned on, the DC current Vdc charges the capacitor C through the current limiting resistor R1 and the transistor Q1. A start-up voltage is output from a collector of the transistor Q1.

When the control device 720 receives the start-up voltage, the transistor 2 is turned on because a base-emitter forward bias is greater than a junction voltage (0.7V). Thus, a current from the start-up device 710 flows into the control device 720 through the power coil L1.

According to the right-hand principle, the direction of a current on a coil determines magnetic pole of a conducted magnetic field. Thus, the salient poles A and B of the stator are conducted to be N-pole, and the poles C and D of the stator are conducted to be S-pole. The pole Sa of the rotor 50 is attracted by the salient pole A and rejected by the salient pole D, the pole Sb thereof is attracted by the salient pole B and rejected by the salient pole C, thereby driving the rotor 50 to rotate.

When the control device 720 is continuously coupled to the DC current Vdc, the control device 720 determine whether the start-up device should stop output of a start-up signal according to electric power stored in the capacitor C.

In FIG. 7, when a voltage level of the capacitor C increases, the reverse base-emitter voltage of the transistor Q1 decreases. When the reverse base-emitter voltage thereof is below the junction voltage (0.7V), the transistor Q1 is turned off, thereby stopping output of the start-up voltage. Thus, the transistor Q2 is turned off, and no current flows through the power coil L1. The conducted magnetic field of the stator disappears, and the rotor 50 rotates by a particular angle, which is 90 degree counterclockwise in this example.

In first state, the permanent magnets 28 on the salient poles C and D attract poles Sa and Sb of the rotor 50 respectively to drive the rotor 50 to continue rotating forward.

In second state, when the permanent magnet 28 attracts the rotor 50 to drive the rotor 50 to rotate, the conduction coil L2 generates a conduction signal, such as a conduction voltage. When the control device 720 receives the conduction signal, the transistor Q2 is turned on. The DC current Vdc flows through the power coil L1. The outer layers of the salient poles A and B of the stator are conducted to be N-pole again, and the poles C and D of the stator are conducted to be S-pole again. Due to the magnetic force of the poles C and D being greater than that of the permanent magnet 28, the rotor 50 is driven by an attraction force between the poles C and D and the poles Sa and Sb to continue rotating forward in the same direction.

In third state, when the salient poles C and D attract the rotor 50 to drive the rotor 50 to rotate, the salient poles C and D and the permanent magnet 28 are magnetically opposite, and thus the conduction coil L2 generates a reverse conduction signal, such as a reverse conduction voltage. Therefore, the reverse base-emitter voltage of the transistor Q2 is below the junction voltage, so the transistor Q2 is turned off.

When the transistor Q2 is turned off, no current flows through the power coil L1. The conducted magnetic field of the stator disappears, and the rotor 50 continues rotating forward in the same direction. Thus, return to the first state.

The torque of the rotor 50 is provided half by the conducted magnetic field generated by the power coil L1 and half by the permanent magnet 28.

Similar operations can be derived for the driving circuit 700 used in the brushless DC motor in FIG. 2.

The voltage detection device 730 detects the conduction signal. When the rotor 50 rotates, the brushless DC motor operates in the first, the second, and the third state alternately. The conduction coil L2 generates the conduction voltage and the reverse conduction voltage alternately, so the transistor Q3 is turn on and off alternately. Thus, a high-low signal is generated, for example a square wave pulse signal. After calculation, the rotational speed of the rotor 50 can be obtained. The high-low signal can be a voltage signal or a current signal. An extra DC current Vcc can be added in the voltage detection device 730 to control a high-low rate of an output voltage.

FIG. 8 is an output voltage to time graph when a brushless DC motor rotates. The horizontal axis represents time t, and the vertical axis represents output voltage Vo. The wave corresponding to T1 is the output wave when the rotational speed of the rotor 50 becomes slow due to dust or other objects. The wave corresponding to T2 is the output wave when the rotor 50 operates normally. The wave corresponding to T3 is the output wave when the rotor 50 stops rotating.

When the rotor 50 stops rotating, the conduction coil L2 stops generating the conduction voltage, the transistors Q1, Q2, and Q3 are all turned off. Thus, no undesired current flows into the power coil L1, the transistors Q1, Q2, and Q3, and the conduction coil L2.

In some embodiments of a brushless DC motor, when the rotor 50 stops rotating, no undesired current flows into any active component or coil of the driving circuit, preventing overheating or burn-out. Any malfunctions can be easily eliminated by coupling the brushless DC motor to the DC current Vdc again, to restore operation.

Thus, the disclosed driving device 700 can potentially stabilize the brushless DC motor.

The start-up device 710 further comprises a power-releasing device comprising a diode D1 and a resistor R2. When the start-up device 710 is disconnected from the DC current Vdc, the power-releasing device releases electric power stored in the capacitor C by discharging the capacitor C through the diode D1 and the resistor R2. Thus, the capacitor C is re-charged when the start-up device 710 is again coupled to the DC current Vdc.

An embodiment of the stator structure is appropriate for a motor or a fan with coils axially or radially wound thereon.

While the invention has been described by way of example and in terms of several embodiments, it is to be understood that the invention is not limited thereto. To the contrary, it is intended to cover various modifications and similar arrangements (as would be apparent to those skilled in the art). Therefore, the scope of the appended claims should be accorded the broadest interpretation so as to encompass all such modifications and similar arrangements. 

1. A stator structure, comprising: at least a magnetic conductive layer comprising a plurality of first poles; and at least a first auxiliary magnetic polar layer disposed above the magnetic conductive layer, below the magnetic conductive layer, or between two magnetic conductive layers, and comprising at least a second pole and a third pole, and the second pole comprises permanent magnetic material.
 2. The stator structure as claimed in claim 1, wherein the magnetic conductive layer comprises ferromagnetic material or soft magnetic material.
 3. The stator structure as claimed in claim 1, wherein the permanent magnetic material is a permanent magnet, a rubber magnet, a plastic magnet, or a magnet-cored plastic.
 4. The stator structure as claimed in claim 1, wherein the third pole is a non-magnetic conductive material pole, a permanent magnetic material pole, a ferromagnetic material pole, a soft magnetic material pole, a rubber magnet, a plastic magnet, a magnet-cored plastic pole, or a hole.
 5. The stator structure as claimed in claim 1, wherein the third pole comprises permanent magnetic material, and the second pole and the third pole are magnetically opposite.
 6. The stator structure as claimed in claim 1, further comprising at least a second auxiliary magnetic polar layer disposed below the magnetic conductive layer or between two magnetic conductive layers and comprising at least a fourth pole and a fifth pole, wherein the fourth and the fifth poles are disposed corresponding to positions of the second and the third poles respectively, and the fourth pole comprises permanent magnetic material.
 7. The stator structure as claimed in claim 6, wherein the fifth pole is a non-magnetic conductive material pole, a permanent magnetic material pole, a ferromagnetic material pole, a soft magnetic material pole, a rubber magnet, a plastic magnet, a magnet-cored plastic pole, or a hole.
 8. The stator structure as claimed in claim 6, wherein the fifth pole comprises permanent magnetic material, and the fourth pole and the fifth pole are magnetically opposite.
 9. The stator structure as claimed in claim 6, wherein the second pole and the fourth pole are magnetically identical.
 10. A stator structure, comprising: at least a magnetic conductive layer comprising a plurality of first poles; and at least a first auxiliary magnetic polar layer comprising at least a second pole, wherein the second pole comprises permanent magnetic material.
 11. The stator structure as claimed in claim 10, wherein the first auxiliary magnetic polar layer and the magnetic conductive layer are interlaced.
 12. The stator structure as claimed in claim 10, wherein the first auxiliary magnetic polar layer is disposed above the magnetic conductive layer, below the magnetic conductive layer, or between two magnetic conductive layers.
 13. The stator structure as claimed in claim 10, wherein the first auxiliary magnetic polar layer further comprises at least a third pole and the total number of the second and the third poles is equal to that of the first poles.
 14. The stator structure as claimed in claim 13, wherein the third pole is a non-magnetic conductive material pole, a permanent magnetic material pole, a ferromagnetic material pole, a soft magnetic material pole, a rubber magnet, a plastic magnet, a magnet-cored plastic pole, or a hole.
 15. The stator structure as claimed in claim 13, wherein the third pole comprises permanent magnetic material, and the second pole and the third pole are magnetically opposite.
 16. The stator structure as claimed in claim 10 further comprising at least a second auxiliary magnetic polar layer comprising at least a fourth pole and a fifth pole, wherein the fourth and the fifth poles are disposed corresponding to positions of the second and the third poles respectively, and the fourth pole comprises permanent magnetic material.
 17. The stator structure as claimed in claim 16, wherein the second auxiliary magnetic polar layer and the magnetic conductive layer are interlaced.
 18. The stator structure as claimed in claim 16, wherein the second auxiliary magnetic polar layer is disposed above the magnetic conductive layer, below the magnetic conductive layer, or between two magnetic conductive layers.
 19. The stator structure as claimed in claim 16, wherein the first and the second auxiliary magnetic polar layers are symmetrically disposed or interlaced.
 20. The stator structure as claimed in claim 16, wherein the second pole and the fourth pole are magnetically identical. 